Ozone Adhesion Process for Insulating Container Manufacture

Patent metadata

Field	Value
Publication number	US-2016279840-A1
Application number	US-201514665494-A
Country	US
Kind code	A1
Filing date	Mar 23, 2015
Priority date	Mar 23, 2015
Publication date	Sep 29, 2016
Grant date	—

Abstract

Systems and methods for improving adhesion of an insulating foam to a molded polymeric insulating structure through use of ozone gas for functionalization of molded polymeric surfaces of an internal cavity of the insulating structure.

First claim

We claim:

1 . A method of manufacturing an insulating container, comprising:
molding an external structure of the insulating container from a polymer, the external structure comprising:
an inner trough;
an outer shell coupled to the inner trough by a top edge surface;
an internal cavity spaced between the inner trough and the outer shell and extending around four sides and a base of the external structure;
a first opening extending into the internal cavity at a first corner of a base surface of the outer shell;
a second opening extending into the internal cavity at a second corner, opposite the first corner, of the base surface of the outer shell;
positioning the external structure such that the second opening is above the first opening; injecting an ozone gas containing 5-7.5% ozone into the first opening; filling at least 80% of the cavity with the ozone gas to displace a mass of air out through the second opening; flushing the cavity with air to remove ozone gas from the cavity; and filling the cavity with an insulating foam.

2 . The method of claim 1 , wherein a volume flow rate of the ozone gas into the first opening is such that a volume of the cavity is filled in at least 4 minutes.

3 . The method of claim 1 , wherein a volume flow rate of the ozone gas into the first opening is such that a volume of the cavity is filled in at most 10 minutes.

4 . The method of claim 1 , wherein the flushing the cavity with air further comprises flushing for at least 2 minutes.

5 . The method of claim 1 , wherein the flushing the cavity with air to remove ozone gas comprises removing at least 95% of the ozone gas from the cavity.

6 . The method of claim 1 , wherein the flushing the cavity with air to remove ozone gas comprises removing at least 97% of the ozone gas from the cavity.

7 . The method of claim 1 , wherein the flushing the cavity with air to remove ozone gas comprises removing at least 99% of the ozone gas from the cavity.

8 . The method of claim 1 , wherein the molding of the external structure utilizes a rotational molding process.

9 . The method of claim 1 , wherein the polymer is polyethylene.

10 . The method of claim 1 , wherein the insulating foam is polyurethane.

11 . The method of claim 1 , wherein the ozone gas is injected at room temperature.

12 . The method of claim 1 , wherein the outer shell has a substantially cuboidal shape.

13 . A method for producing an insulating structure, comprising:
(a) molding an outer shell of the insulating structure from a polymer, the outer shell comprising:
an internal cavity;
a first opening extending into the internal cavity;
a second opening extending into the internal cavity;
(b) positioning the outer shell such that the second opening is above the first opening; (c) injecting an ozone gas containing 5-7.5% ozone into the first opening; (d) filling the cavity with the ozone gas to displace a mass of air out through the second opening; (e) at a time after step (d), filling the cavity with a gas to remove at least 97% of the ozone gas from the cavity; and (f) injecting an insulating foam into the cavity.

14 . The method of claim 13 , wherein a volume flow rate of the ozone gas into the first opening is such that a volume of the cavity is filled in at least 4 minutes.

15 . The method of claim 13 , wherein a volume flow rate of the ozone gas into the first opening is such that a volume of the cavity is filled in approximately 4-10 minutes.

16 . The method of claim 13 , wherein step (e) begins approximately 4 to 10 minutes after step (c) began.

17 . The method of claim 13 , wherein step (e) is completed within no more than two minutes after step (e) began.

18 . The method of claim 13 , wherein step (d) of filling the cavity with the ozone gas to displace a mass of air out through the second opening comprises filling at least 90% of the cavity with ozone gas.

19 . The method of claim 13 , wherein step (d) of filling the cavity with the ozone gas to displace a mass of air out through the second opening comprises filling at least 95% of the cavity with ozone gas.

20 . The method of claim 13 , wherein the molding of the outer shell utilizes a rotational molding process.

21 . The method of claim 13 , wherein the polymer is polyethylene.

22 . The method of claim 13 , wherein the gas is air.

23 . The method of claim 13 , wherein the first opening is adjacent a bottom portion of the internal cavity and the second opening is adjacent a top portion of the internal cavity.

24 . A method for manufacturing a cooler, comprising:
(a) molding an external structure of the cooler from polyethylene, the external structure comprising:
an inner trough;
an outer shell coupled to the inner trough by a top edge surface;
an internal cavity spaced between the inner trough and the outer shell and extending around four sides and a base of the external structure;
a first opening extending into the internal cavity at a first corner of a base surface of the outer shell;
a second opening extending into the internal cavity at a second corner, opposite the first corner, of the base surface of the outer shell;
(b) positioning the external structure such that the second opening is above the first opening; (c) injecting an ozone gas containing 5-7.5% ozone into the first opening; (d) filling at least 90% of the cavity with the ozone gas in at least four minutes to displace a mass of air out through the second opening; (e) flushing the cavity with air for at least two minutes to remove ozone gas from the cavity; and (f) filling the cavity with polyurethane insulating foam.

25 . The method of claim 24 , wherein the outer shell has a substantially cuboidal shape.

Assignees

• Yeti Coolers Llc

Inventors

• French John
• Nugent Paul
• Laxamana Francis
• Adarlo Argel

Classifications

• B29K2075/00

  Use of {PU, i.e.} polyureas or polyurethanes {or derivatives thereof}, as moulding material · CPC title

• B29C41/042

  by rotating a mould around its axis of symmetry (for concrete B28B21/30) · CPC title

• B29C44/18

  Filling preformed cavities {(B29C44/1204 takes precedence)} · CPC title

• B29K2023/06

  PE, i.e. polyethylene · CPC title

• B29C44/3403 Primary

  Foaming under special conditions, e.g. in sub-atmospheric pressure, in or on a liquid · CPC title